PDF Shop Manual Komatsu PC210i-10 PC210LCi-10 Hydraulic Excavator - 5 MB
This comprehensive shop manual covers the Komatsu PC210i-10 and PC210LCi-10 Hydraulic Excavators, including their intelligent machine control systems.
It contains detailed procedures for testing, adjusting, troubleshooting, and disassembly/assembly of all major components.
This manual is the ultimate resource for service technicians to perform any repair or maintenance task to factory specifications.
It's essential for servicing these technologically advanced excavators.
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--- Page 1 ---
SEN06515-04
HYDRAULIC PC210i -10
EXCAVATOR
PC210LCi -10
SERIAL NUMBERS 451080 and up
--- Page 3 ---
00 Index and foreword
Foreword, safety and general information
How to read the shop manual (ALL-0320-010-A-01-A)
(Rev. 2012/10)
• Some attachments and optional parts described in this shop manual may not be arranged for certain
areas. Contact your Komatsu distributor if one or some of them are required.
• Materials and specifications are subject to change without notice.
• The shop manuals are available for "Machine part" and "Engine part". For the engine, see the shop
manual for the same model of the engine as the one which is mounted on the machine.
Composition of shop manual
• This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of "Structure and function"
serves not only to give an understanding for the structure of each component, but also serves as
reference material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are indicated. This standard value table is
used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for
the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for
the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or
component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the
works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the
criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or
equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.
PC210I-10, PC210LCI-10 00-23
--- Page 4 ---
00 Index and foreword
Foreword, safety and general information
No- Bolt pitch (mm) Hose side Tube side
minal Split flange Sleeve head O-ring (4) Bolt (5) Washer (6)
a b Flange (1)
No. (2) (3)
07379- 01010-
79.4 36.5 07371-51470 07378-11410 07000-13048 01643-31445
01470 81455
07379- 07372-
77.8 42.8 07371-32076 07378-12000 07000-12060 01643-51232
02071 51240
20
07379- 01010-
96.8 44.5 07371-52080 07378-12010 07000-12060 01643-31845
02080 81865
07379- 07372-
24 88.9 50.8 07371-12484 07378-12400 07000-12070 01643-51232
02484 51240
07379- 07372-
30 106.4 62 07371-13010 07378-13000 07000-12085 01643-51645
03010 51650
07372-
34 120.6 69.8 07379-03411 07371-13411 07378-13400 07000-12100 01643-51645
51650
07379- 07372-
40 130.2 77.8 07371-14012 07378-14000 07000-12110 01643-51645
04012 51650
07372-
50 152.4 92 07379-05011 07371-15011 07378-15000 07000-12135 01643-51645
51655
Removal of pipe joints of O-ring boss type
Nominal No. Plug (1) O-ring (2)
08 07040-10807 07002-10823
10 07040-11007 07002-11023
12 07040-11209 07002-11223
14 07040-11409 07002-11423
16 07040-11612 07002-11623
18 07040-11812 07002-11823
20 07040-12012 07002-12034
24 07040-12412 07002-12434
30 07041-13012 07002-13034
33 07040-13316 07002-13334
36 07041-13612 07002-13634
42 07040-14220 07002-14234
52 07040-15223 07002-15234
Removal of pipe joints of taper pipe thread type
PC210I-10, PC210LCI-10 00-47
--- Page 5 ---
01 Specification
Working range drawings
Working range drawings (ALL-2110-001-A-02-A)
PC210I-10 (PC200_ICT-2110-931-A-03-A)
Item Unit PC210I–10
A Max. digging reach mm 9,875
B Max. digging depth mm 6,620
C Max. digging height mm 9,970
D Max. vertical wall digging depth mm 5,980
E Max. dumping height mm 7,110
F Min. dumping height mm 2,645
Max. digging reach at ground mm 9,700
G
level
PC210I-10, PC210LCI-10 01-5
--- Page 6 ---
10 Structure and function
KVGT
Cooling
• Coolant from the cylinder block enters the center housing to cool the KVGT.
• Coolant return flows from the center housing and joins the flow at the EGR cooler outlet piping, then flows
through the water inlet connector to the water pump.
PC210I-10, PC210LCI-10 10-11
--- Page 7 ---
10 Structure and function
Final drive
Final drive (PC220-DF10-041-K-00-A)
1. Level plug
2. No. 1 planetary gear (number of teeth: 42)
3. Drain plug
PC210I-10, PC210LCI-10 10-35
--- Page 8 ---
10 Structure and function
Main pump
When pump delivery is increased
• When the difference between pump delivery pressure (PP) and LS pressure (PLS), in other words, LS
differential pressure (dPLS) decreases (for example, when the control valve opening area increases and
pump delivery pressure (PP) decreases), the combined force exerted by LS pressure (PLS) and spring (4)
pushes spool (6) to the left.
• As spool (6) moves, ports (D) and (E) are interconnected and also connected to the PC valve.
• Since the PC valve and drain port are connected, the pressure between ports (D) and (K) becomes drain
pressure (PT). (PC valve operation will be explained later.)
• The pressure on the large diameter piston side of servo piston (12) becomes drain pressure (PT), and
pump pressure (PP) is constantly transmitted to port (J) on the small diameter end. Accordingly, servo
piston (12) is pushed to the left and the swash plate is moved to increase the discharged volume.
• At this time, when the output pressure from the EPC valve for the LS valve is transmitted to port (G), a
force is applied on piston (7) to move the piston to the right.
• If piston (7) is pushed to the right, setting force of spring (4) is weakened, changing the LS differential
pressure (dPLS) [Difference between oil pressures (PLS) and (PP)] when ports (D) and (E) of spool (6)
are connected.
PC210I-10, PC210LCI-10 10-59
--- Page 9 ---
10 Structure and function
Control valve
1. Unload valve
2: Safety valve for hydraulic drift prevention valve (boom RAISE and arm DUMP)
3. Main relief valve
4. Variable back pressure valve
Arm valve
5. Arm hydraulic drift prevention valve (*1)
6. LS shuttle valve
7. Arm quick return valve
8. Pressure compensation valve (arm IN)
PC210I-10, PC210LCI-10 10-83
--- Page 10 ---
10 Structure and function
Control valve
Operation (ALL-J6PA-044-K-00-A)
When pilot pressure (BP) is shut off
• Since pilot pressure (BP) is shut off, piston (3) is pressed to the left by force of spring (2).
• If the swing lever is moved, swing LS pressure (P1) passing through swing spool (5) enters port (A).
• Swing LS pressure (P1) presses valve (1) to the left, and port (A) and port (B) are interconnected.
• Swing LS pressure (P1) is transmitted from port (A) to LS shuttle valve (8) through port (B).
When pilot pressure (BP) is supplied
• When pilot pressure (BP) is supplied, pilot pressure (BP) moves piston (3) to the right against the force of
spring (2).
• When piston (3) moves to the right, valve (1) disconnects ports (A) and (B).
• Since ports (A) and (B) are disconnected, swing LS pressure (P1) is not transmitted to LS shuttle valve
(8).
• Swing LS pressure (P1) cannot affect other LS circuits, even if it rises.
PC210I-10, PC210LCI-10 10-107
--- Page 11 ---
10 Structure and function
Control valve
2-stage suction-safety valve (PC220-PQJ2-041-K-00-A)
[Installed to port (B) of the service valve]
1. Spring
2. Piston
3. Spring
4. Holder
Function (PC220-PQJ2-042-K-00-A)
• This valve has two settings for its set pressure.
• This valve is set to the low-pressure setting when the pilot pressure is applied to it from the attachment
circuit selector solenoid valve.
• ON/OFF of the pilot pressure changes the set pressure according to the type of the installed attachment
(breaker, crusher, etc.).
• The set pressure of this valve is determined by the load at installed length of spring (1). (High-pressure
side)
• The set pressure of the low-pressure setting is determined by the travel of the piston.
Operation (ALL-PQJ2-044-K-00-A)
When pilot pressure (P) is shut off (high pressure setting)
• Since pilot pressure (P) is shut off, piston (2) is pressed to the left by force of spring (3). [Load at installed
height of spring (1) < Load at installed height of spring (3).]
PC210I-10, PC210LCI-10 10-131
--- Page 12 ---
10 Structure and function
Travel motor
Braking while travelling downhill
• When the machine almost run out of control during downhill travel, the motor runs idle and the pressure of
the inlet side circuit decreases.
• The pressure in chamber (S1) decreases through orifices (E1) and (E2).
• When the pressure in chamber (S1) becomes lower than the spool selector pressure, spool (19) is
returned to the left by the reaction force of spring (20) and outlet passage (B1) is throttled.
• The pressure of the motor outlet side circuit increases and rotational resistance is generated in the motor,
preventing the machine from running out of control.
• Spool (19) moves to a position where the two forces acting on the spool balance with each other; one is
the force exerted by the pressure in the motor outlet port and the other is the sum of the force due to
machine's own weight and the force exerted by the pressure in the motor inlet port.
• Narrowing down the motor outlet side circuit in this way allows the machine to travel at a speed that
matches the pump discharged volume.
PC210I-10, PC210LCI-10 10-155
--- Page 13 ---
10 Structure and function
PPC valve
2nd-line attachment PPC valve (PC-PL2A-041-K-00-A)
(Machines ready for installation of attachment)
a PPC: Abbreviation for Proportional Pressure Control
a For details of operation, see "Work equipment and Swing PPC valve".
P: From self-pressure reducing valve
P1: To control valve (service valve 2 port)
P2: To control valve (service valve 2 port)
T: To hydraulic tank
PC210I-10, PC210LCI-10 10-179
--- Page 14 ---
10 Structure and function
Electrical control system
PC210I-10, PC210LCI-10 10-203
--- Page 15 ---
10 Structure and function
Electrical control system
Swing control function (PC-JA01-042-K-01-A)
1. Battery disconnect switch
2. Battery
3. Battery relay
4. Fusible link
5. Fuse box
6. Swing brake cancel switch
7. Swing lock switch
8. Pump controller
9. Machine monitor
10. Oil pressure switch
11. Oil pressure sensor
12. Main pump
13. Control valve
13a. Self-pressure reducing valve
13b. Merge-divider valve
13c. Travel junction valve
14. Swing motor
14a. 2-stage relief valve
15. Swing holding brake solenoid valve
16. 2-stage swing relief solenoid valve
Input and output signals
a. Swing brake cancel switch signal
b. Swing holding brake solenoid valve drive signal
c. CAN signal
d. Swing lock switch signal
e. 2-stage swing relief solenoid valve drive signal
f. Oil pressure sensor signal
g. Oil pressure switch signal
PC210I-10, PC210LCI-10 10-227
--- Page 16 ---
10 Structure and function
Electrical control system
1. Target speed of arm cylinder
2. EPC current
Automatic stop control function (PC200_ICT-LL80-270-K-10-A)
Function
• This function controls the work equipment to stop automatically in order not to damage the design pad.
Operation
When boom LOWER is operated
A: Boom RAISE PPC circuit
B: Boom LOWER PPC circuit
1. Work equipment controller
2. PPC pressure reducing EPC valve
3. PPC pressure sensor
4. Boom spool (control valve)
5. Boom cylinder
6. Work equipment control lever
7. Boom RAISE EPC valve
• When the boom LOWER is operated, the boom lowers and the bucket blade edge moves toward the
design pad. (Bucket blade edge speed (S1))
PC210I-10, PC210LCI-10 10-251
--- Page 17 ---
10 Structure and function
Electrical control system
DRC26-40P(B) [CN-CS03]
Input/output
Pin No. Signal name
signal
1 Continuous power supply (24 V) Input
2 Solenoid power supply (24 V) Input
3 (*1) -
4 Battery relay signal Output
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
9 Model selection 2 Input
10 Power supply (24 V) Input
11 Continuous power supply (24 V) Input
12 Solenoid power supply (24 V) Input
13 (*1) -
14 Starting switch ACC signal Input
15 (*1) -
16 (*1) -
17 (*1) -
18 (*1) -
19 (*1) -
20 Starting switch ACC signal Input
21 Controller GND Input
22 Solenoid power supply (24 V) Input
23 (*1) -
24 Starting switch ACC signal Input
25 (*1) -
26 (*1) -
27 (*1) -
28 (*1) -
29 (*1) -
30 Starting switch C signal Input
31 Controller GND Input
32 Controller GND Input
33 Controller GND Input
34 System operating lamp Output
35 (*1) -
36 (*1) -
37 (*1) -
38 (*1) -
39 Model selection 5 Input
40 (*1) -
*1: Never connect these pins. Malfunctions or failures may occur.
PC210I-10, PC210LCI-10 10-271
--- Page 18 ---
10 Structure and function
Machine monitor system
Gauge
Gauge Item displayed Description Remarks
Temperature Monitor • Indicates
Range
(°C) background corresponding
W1 105 Red temperature range.
Engine coolant • The alarm buzzer
W2 102 Red
temperature sounds at 105°C or
gauge (*1) W3 100 Blue higher.
W4 85 Blue • If background color is
W5 60 Blue white, warm up
W6 30 White engine.
Temperature Monitor • Indicates
Range
(°C) background corresponding
H1 105 Red temperature range.
• The alarm buzzer
Hydraulic oil H2 102 Red
sounds at 105°C or
temperature H3 100 Blue higher.
gauge (*1) H4 85 Blue • If background color is
H5 40 Blue white, warm up
hydraulic
H6 20 White components.
Monitor • Indicates
Range Quantity (l)
background corresponding level
F1 304 Blue range.
F2 245 Blue
Fuel gauge (*1)
F3 200 Blue
F4 100 Blue
F5 60 Blue
F6 41 Red
Segment Load level • Indicates
Light to instantaneous fuel
Green 1 to 8 consumption
medium
(average of fuel
consumption by 3
seconds) in 10 steps.
ECO gauge (*2)
(Displays when "ECO
Orange 9, 10 Heavy Guidance" o
"Configurations" o
"ECO Gauge
Display" in user menu
is "ON".)
• Indicates
accumulated engine
operating hours
(alternator is
Service meter 00000.0 h to 99999.9 h generating).
(Press F4 switch to
change to clock
display.)
PC210I-10, PC210LCI-10 10-295
--- Page 19 ---
10 Structure and function
Sensor
EGR valve lift sensor (ENG-A9S2-041-K-00-A)
EGR: Abbreviation for Exhaust Gas Recirculation
1. O-ring (small)
2. O-ring (large)
3. Sensor
4. Connector
Function (ENG-A9S2-042-K-00-A)
• This sensor, installed to EGR valve in the engine, detects the EGR valve opening to output the
corresponding variable voltage.
Output characteristics
• The relation between stroke and output voltage is as shown in the following graph.
PC210I-10, PC210LCI-10 10-319
--- Page 20 ---
10 Structure and function
Sensor
Stroke and reset sensor for bucket cylinder (PC200_ICT-LCV8-041-K-00-A)
a Do not disassemble this since it needs to be adjusted for maintaining the performance after reassembly.
1. Connector
2. Stroke sensor
3. Tube
4. Hose
5. Reset sensor
PC210I-10, PC210LCI-10 10-343
--- Page 21 ---
20 Standard value tables
Standard value table for machine
Hydraulic pump
Machine model PC210i-10, PC210LCi-10
Discharged Discharged
volume volume
Item Measurement condition Unit
Standard Repair limit
value
• Pump rotation speed (rpm): 1,700 rpm
• PC-EPC current value (mA): 440mA
• Test pump discharged pressure (MPa {kg/
cm2})
: P1 Q Q
Performance of
• Other pump discharged pressure (MPa {kg/ l/mIn
hydraulic pump (See graph) (See graph)
cm2})
: P2
• Average discharged pressure (MPa {kg/
cm2})
: Pp = (P1 + P2) / 2
a Allow pump discharge pressures P1 and P2 as close as possible to the average pressure when
measuring.
Avoid measuring in the proximity of turning point of the graph because the error increases there.
a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the
specified speed by using the fuel control dial, take the pump discharged volume and the engine speed at
the time of measurement, and use them as a base for calculating the pump discharged volume at the
specified speed.
PC210I-10, PC210LCI-10 20-15
--- Page 22 ---
30 Testing and adjusting
Related information on testing and adjusting
Testing/ Sym-
Q'ty
Adjusting item bol Part No. Part name Remarks
Commercially
1 Total station 1
available
Measurement target W2 is a
2 2A5-98-21210 Measurement target 1 component of blade edge
measuring jig W4.
Commercially
3 Marker 1
available
Special jig for measuring
2A5-98-05011 blade edge 1
2A5-98-21111 • Bracket 1
2A5-98-21121 • Bracket 1
Calibration of
2A5-98-21130 • Bracket 1
boom
dimensions 2A5-98-21140 • Bracket 1
and arm 2A5-98-21151 • Pin 2
dimensions W 2A5-98-21161 • Block 1
with total 2A5-98-21220 • Magnet 6
station (Arm 2A5-98-21230 • Reflector plate 1
Top
Calibration) 4 2A5-98-21240 • Adapter 1
2A5-98-21250 • Bolt 2
2A5-98-21260 • Bolt 2
2A5-98-21270 • Bolt 3
2A5-98-21310 • Washer 2
17A-711-7850 • Washer 2
2A5-98-21330 • Pole 1
2A5-98-21340 • Collar 1
22J-973-3520 • Bolt 1
01252-90616 • Washer 3
01640-20610 • Washer 1
PC210I-10, PC210LCI-10 30-7
--- Page 23 ---
30 Testing and adjusting
Engine and cooling system
Testing return circuit a If the engine cannot be started, you can
1. Remove cover (1). measure the fuel pressure while rotating the
engine using the starting motor. However, to
protect the starting motor, do not rotate the
engine for more than 20 seconds
continuously.
a If the pressure in the return circuit is in the
following range, it is proper.
At high idle Max. 18.6 kPa
Cranking {Max. 0.19 kg/cm2}
2. Remove joint bolt (2) of the fuel return hose
between the supply pump and fuel cooler.
5. After completing measurement, remove the
measuring tools and return the machine to the
original condition.
3 Joint bolt (2):